Impact of fiber velocity on pressure distribution in the melt impregnation wedge area of thermoplastic composites using nonlinear Darcy law mathematical model

Thermoplastic composites offer high strength and recyclability but optimal fiber impregnation remains challenging due to the interaction among fiber velocity, pressure and viscosity. This research investigates the impact of velocity (0.5, 0.8, 1 and 1.5 m/min) on pressure distribution in wedge area of melt impregnation at a constant temperature of 250 °C using of glass fiber polypropylene composite (GFPP), to validate the experimental results a nonlinear Darcy law flow mathematical model was developed, to calculate the pressure in wedge area at different fiber velocity MATLAB was used for simulation. According to MATLAB simulation and SEM analysis show lower fiber velocity results in better impregnation quality with minimum void content and lower pressure in wedge area compared to higher velocities due to low velocity allowing more time for the resin to impregnate onto the fiber. This model-based approach provides insights for optimizing melt impregnation parameters and supporting the production of high-quality thermoplastic composites.